Flat article processing apparatus

ABSTRACT

An underfolder device for turning under the edge of a previously folded piece of limp material passing through the device for underfolding the material in readiness for automatically sewing an underfolded hem thereon, such as on bedsheets and similar articles.

United States Patent Inventor App]. No. Filed Patented Assignee Thomas L. Flanagan Killingworth, Conn.

Dec. 18, 1969 Dec. 21, 1971 Wagner Research Corporation New York, N.Y.

Original application May 13, 1968, Ser. No. 728,664, now Patent No. 3,489,113. Divided and this application Dec. 18, 1969, Ser. No. 886,325

FLA'I ARTICLE PROCESSING APPARATUS 4 Clllms, 4 Drnwlng Flgs.

U.S.Cl 112/147, 1 12/ 141 Int. Cl D051) 35/08 [50] Field of Search 112/147, 141,121.15, 121.12, 121.1],2

[5 6] References Cited UNlTED STATES PATENTS 3,012,603 12/1961 Newsome et al 112/147 UX 3,142,277 7/1964 Jordan 1. 112/147 X 3,192,885 7/1965 Timm... 1l2/l2l.15 3,262,409 7/1966 Tucci 112/147 3,296,986 1/1967 Gansl 112/147 X Primary Examiner-James R. Boler AlmrneyBryan. Parmelee, Johnson & [Bollinger ABSTRACT: An underfolder device for turning under the edge of a previously folded piece of limp material passing through the device for underfolding the material in readiness for automatically sewing an underfoldedl hem thereon, such as on bedsheets and similar articles.

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INVENTOR THOMASL. FLAM4AIY FLAT ARTICLE PROCESSING APPARATUS This application is a division of application Ser. No 728,664, filed May 13, 1968, now U.S. Pat. No. 3,489,l 13.

The present invention relates to apparatus for automatically processing bulk pliable material, such as cloth, for example, into finished flat articles, such as flat bedsheets, for example. In particular, the present invention relates to improved integrated apparatus for automatically processing such material from a bulk or roll supply into finished flat bedsheets, as fully shown in U.S. Pat. No. 3,489,113, issued Jan. 13, 1970, of which the present application is a division.

Although current technology provides integrated apparatus which automatically processes bulk material into finished articles, certain of the individual functions of the present improved integrated apparatus are great advances over corresponding individual functions found in currently used apparatus. The present improved integrated apparatus of the present invention provides a greatly improved system which advantageously employs components or functioning units which are functionally compatible to each other and to the system as a whole. In order to accomplish more functional compatibility among the cooperating units of the system than heretofore available, certain of the functioning units were created which facilitate compact handling of the pieces of material, hereinafter referred to as blanks" during processing.

Each workline of the apparatus shown in said U.S. patent includes a right shoulder and a left shoulder, separated by the transfer channel in which the main portion of the body of a blank is transferred in a confined, collected condition. The edges of the blank, between the leading and trailing ends are held on the shoulders where work is preformed on each edge, separately. Each edge is passed through a continuous flow, passive folding device and an'underfolder to form a folded hem on each blank in readiness for sewing.

An object is to provide an improved flat article processing apparatus which conveys a flat article blank along the workline with the body of the blank in a confined, collected condition, and which forms an underfolded hem portion on each blank in a continuous flow motion.

The other objects will become apparent from reading the following detailed description of the invention with reference to the accompanying drawing in which:

FIG. 1 is a perspective view of part of one shoulder and transfer channel of one workline showing the rotary indexable storage and retrieval device for a self-starting continuous flow folder and underfolder with cut blanks being conveyed along the workline and passing through the self-starting continuous flow folder and the underfolder.

FIG. 2 is a plan view of part of one shoulder of one workline showing the continuous flow folder and underfolder.

FIG. 3 is a cross section elevation view along the lines DD of FIG. 2.

FIG. 4 is a view of the underfolder with the components exploded.

Just prior to the leading edge of the blank entering the hemfolding device the transfer speed is reduced to essentially the sewing speed of the sewing machine (not shown) positioned at the end of the hem-folding device. The blank is then transferred or conveyed along so that the cut edge passes through the hem folder which folds the hem in an over fold arrangement and provides a hem with a finished edge by folding the cut edge under. This is clearly seen in FIG. I and will be fully described below with reference to FIGS. 1, 2, and 3.

When the folded edge exits from the folding apparatus the hen is sewn in place by a sewing machine as the blank is conveyed through the sew point of the sewing machine. This sewing machine may be a conventional lock-stitch sewing machine.

In FIG. 1 two sheet blanks 25B and 25B" are shown to illustrate fully the confined, collected condition of the sheet blank body in the transfer channel 50, and the relation of the edge of the sheet blank 25E to the self-starting folding device. FIG. 2 shows, in plain view the relation of the edge of the sheet blank 25E to the self-starting folding device and also shows the natural flow curve and folding action generated by the self-starting folding device. A natural flow folding device similar to the device shown in FIGS. 11 and 2 the sheet blank 25B is conveyed or transferred along the workleg with the edge 25E (one edge is shown) on the shoulder 51 and the other edge (not shown) on shoulder 52. A portion of the body of the sheet blank is collected and confined in the transfer channel 50 and is shown in a folded condition at 25F. The transfer belt 93' holds the edge 25B and adjacent portion of the sheet blank on the shoulder 51 and! also conveys the sheet blank on the shoulder 52.

As the sheet blank is conveyed along the workleg by the transfer belts, the corners of the leading edge of the sheet blank approach the self-starting hem folder. The leading corners of the sheet proceed up a ramp while the portion of the sheet blank adjacent to the edge passes under ply-separator plate 156/157. The holddown portion of the plate has an uplifted or ski-toe to ensure that the sheet blank passes under the holddown portion of the ply-separator plate. The combination of elevating the edge and holding down the body of the sheet creates a condition where the sheet blank folds itself. This is clearly seen in FIG. 1. The sheet blank is guided or urged, passively, into a condition where by the natural stiffness of the material is overcome and the sheet material folds in a natural flow, folding along the natural flow guide bar 159. The edge 25E may be easily followed by observing FIG. 1. The newly created fold is held against the fold stop plate 160 with the edge 25E on the upper surface of the ply-separator plate 157. The self generated fold may be seen at 25F. A more detailed description of the natural flow folder is presented in my copending application Ser. No. 718,445 filed Apr. 3, 1968.

When the leading edge of the sheet blank exits from the natural flow folder at 161, the edge 2515. is presented to an underfolder. The underfolder is illustrated in exploded view in FIG. 4 and seen in the FIGS. 1 and 2. The edge 25E at position 161 is fed from the natural flow folder device, which is essentially an over folder, to the underfolder. It will be noted that the edge 255 has been turned over from the point at which the edge 25E proceeds up the ramp 155 to the position 161.

The underfolder is a passive folding device made of four individually folded and/or contoured pieces which may be and essentially are combined externally, with respect to the folding channel. This feature distinguishes su-ch passive underfolder device from other passive underfolders in that other passive folders used for providing small under folds are made from two or more individually folded and/or contoured pieces or components which are coupled or combined internally, with respect to the folding channel.

The underfolder is held in position by an overhead bracket 162. The bracket 162 may be coupled to the overhead structure (not shown). Such structure over the part of the workleg where the folding devices are positioned has been eliminated for the sake of clarity.

The baseplate 163 of the underfolder is a generally rectangular piece to which the bracket 162 is coupled. The baseplate is held suspended above the surface of the body of the sheet blank but at a level so that the edge 25E passes out of the natural flow folder at position 161 and passes over the upper surface of the baseplate 163. This is aided by the ply-separator plate 157 of the natural flow folder on which the edge 25E lies after the overfold has been created. The baseplate 163 has a folded edge 164 which is contoured to form a ramp which is sloped toward the ends of the baseplate and has it apex at approximately the longitudinal center of the baseplate. The for- IOIOIS 0217 with the ramp portion of plate 163 and form an inclined channel along which the edge 25E of the sheet blank travels. The edge 25B is essentially isolated from the rest of the sheet blank while passing along the inclined channel. An end inverting plate 171 and an end underpositioning plate 172 combine on the baseplate 163 to invert the edge 2513 into an underfold condition. It will be noted that the plate 171 has one end which is noninterfering as respects the edge 255, this noninterfering edge may be coupled to the baseplate 163 so that the edge interfering portion is positioned in line with the inclined channel. The plate 172 also includes a displaced edge portion which may be coupled to base 163 over the displaced edge portion of plate 171. This type of construction of the preformed plated provides an underfolder having an edgedirecting channel which is free as respects to coupling of the respective parts.

FIG. 3 shows the sheet blank 25 with the overfold at 25F and the edge 25E folded under to provide a hem with the inside edge finished in a triple layer of material.

in order to secure the triple folded hem a sewing machine is provided FIG. 1 shows a broken line 102 which represents the needle of the sewing machine. FIG. 2 shows an X and a broken line 173 which represents the stitches sewn on the triple layer. The stitches 173 are also seen in FIG. 1.

Thus 1 have described the preferred embodiment of my invention. Changes, alterations and substitutions may be made, as will be familiar to those skilled in the art, without departing from the spirit of the invention as defined in the appended claims.

What is claimed is:

1. A device for underfolding the edge of a piece of limp material passing through said device including:

a baseplate having a first longitudinal edge folded over itself forming a ramp having an apex intermediate the ends and sloped toward both ends of said base with the fold at one end folded tight, and the fold at the other end folded with a space between the folded-over portion and the base,

a first plate cooperating with the sloped ramp for forming an inclined channel, said first plate including an externally extending lip coupling said first plate, to said baseplate external to said inclined channel,

a material edge inverting plate having a noninterfering edge and another edge positioned in line with the inclined channel for interfering with the material, said noninterfering edge coupling said inverting plate to said baseplate and a material edge underpositioning plate forming an overhead material guide channel cooperating with said inclined channel, said underpositioning plate including a remote edge portion coupling said underpositioning plate to said baseplate in the region of said noninterfering edge of said material edge inverting plate,

2. A multicomponent material folding device for underfolding the edge of a piece of limp material passing through said device in which the components are joined externally to the fold-forming structure to form a limp material edge-folding channel free from parts junctions, said underfolding device including:

a baseplate having a first longitudinal edge folded over forming a ramp having an apex intermediate the ends of said plate with its forward end folded tight and a space at the other end thereof,

a first plate spaced above the upwardly inclined ramp portion of said base plate for forming an inclined channel for directing the edge of said limp material upward along said ramp, said first plate having an externally extending lip coupling said first plate with said baseplate remote from said inclined channel,

a material edge inverting plate having a noninterfering lip and an edge directing surface, said noninterfering lip coupling said material edge inverting plate to said baseplate so that said edge directing surface is aligned with and adjacent to said inclined channel, said material edge directing surface directing the edge of material passing along said inclined channel to a position under the folded ramp portion of said baseplate and a fold-tightening plate forming an overhead channel connecting with said inclined channel, said fold-tightening plate including an edge remote from said overhead channel coupling said fold-tightening plate to said baseplate at a position remote from said edge-folding channel.

3. A multicomponent material folding device for folding the edge of a piece of limp material passing through said device in which the components are externally coupled to form a limp material edge folding channel free from coupled parts, said folding device including:

a baseplate having a first longitudinal edge folded for forming a ramp having an apex intermediate the ends of said plate and sloped toward both ends, folded tight at the entrance end and folded with a space at the exit end to permit the underfolded edge of the material to pass through said space,

a first plate cooperating with the folded portion of said baseplate for forming an upwardly inclined channel from the entrance end to the apex for directing the edge of limp material passing therethrough upward, said first plate having an external lip coupling with said baseplate remote from said inclined channel,

a material edge underguide plate forming an overhead channel overlapping a portion of said upwardly inclined channel and extending therebeyond for directing the upwardly directed edge under said inclined ramp for underfolding the edge of said material, said underguide plate including an edge remote from said overhead channel coupling said material edge underguide plate to said baseplate remote from said overhead channel and a fold-tightening plate for forming a fold-tightening channel connecting with said overhead channel, said fold-tightening plate including a lip remote from said fold-tightening channel coupling said fold-tightening plate to said baseplate at a position remote from said fold-tightening channel.

4. An apparatus for processinga sheet of limp material into flat articles such as bedsheets, towels, drapes, covers, and the like, in which a cut edge of the limp materials is folded over to form a major fold and then the cut edge of the limp material is underfolded beneath said major fold in readiness for stitching to form a finished hem of the fiat article, an underfolder device for underfolding the cut edge beneath a major fold thereof comprising:

a baseplate having an edge portion thereof folded up and over above the baseplate to form an inclined ramp having an elevated apex intermediate said ramp,

said ramp extending upwardly to said apex at the forward end of the baseplate and extending downwardly form said apex to the rear end of the baseplate,

said folded portion of said baseplate being spaced above the baseplate at the rear end of the baseplate to provide clearance for the underfolded cut edge to pass beneath the downwardly extending portion of said ramp,

a first plate spaced above the upwardly sloping portion of said ramp for defining an upwardly sloping channel,

an extending part of said first plate extending away from said ramp and connected to said base at a position remote from said upwardly sloping channel,

an inverting plate having a tapered portion adjacent to and aligned with the downwardly sloping portion of the ramp for deflecting the cut edge into the clearance space beneath said downwardly sloping ramp portion,

an extending part on said inverting plate extending away from said ramp and connected to said base at a position remote from said ramp,

a fold-tightening plate positioned above and spaced from the downwardly sloping portion of the ramp defining a fold-tightening channel, and

an extending part on said fold-tightening plate extending away from said ramp and connected to said base at a position removed from said ramp.

* 11 1* It t me: IOIOIS 0710 

1. A device for underfolding the edge of a piece of limp material passing through said device including: a baseplate having a first longitudinal edge folded over itself forming a ramp having an apex intermediate the ends and sloped toward both ends of said base with the fold at one end folded tight, and the fold at the other end folded with a space between the folded-over portion and the base, a first plate cooperating with the sloped ramp for forming an inclined channel, said first plate including an externally extending lip coupling said first plate, to said baseplate external to said inclined channel, a material edge inverting plate having a noninterfering edge and another edge positioned in line with the inclined channel for interfering with the material, said noninterfering edge coupling said inverting plate to said baseplate and a material edge underpositioning plate forming an overhead material guide channel cooperating with said inclined channel, said underpositioning plate including a remote edge portion coupling said underpositioning plate to said baseplate in the region of said noninterfering edge of said material edge inverting plate.
 2. A multicomponent material folding device for underfolding the edge of a piece of limp material passing through said device in which the components are joined externally to the fold-forming structure to form a limp material edge-folding channel free from parts junctions, said underfolding device including: a baseplate having a first longitudinal edge folded over forming a ramp having an apex intermediate the ends of said plate with its forward end folded tight and a space at the other end thereof, a first plate spaced above the upwardly inclined ramp portion of said base plate for forming an inclined channel for directing the edge of said limp material upward along said ramp, said first plate having an externally extending lip coupling said first plate with said baseplate remote from said inclined channel, a material edge inverting plate having a noninterfering lip and an edge directing surface, said noninterfering lip coupling said material edge inverting plate to said baseplate so that said edge directing surface is aligned with and adjacent to said inclined channel, said material edge directing surface directing the edge of material passing along said inclined channel to a position under the folded ramp portion of said baseplate and a fold-tightening plate forming an overhead channel connecting with said inclined channel, said fold-tightening plate including an edge remote from said overhead channel coupling said fold-tightening plate to said baseplate at a position remote from said edge-folding channel.
 3. A multicomponent material folding device for folding the edge of a piece of limp material passing through said device in which the components are externally coupled to form a limp material edge folding channel free from coupled parts, said folding device including: a baseplate having a first longitudinal edge folded for forming a ramp having an apex intermediate the ends of said plate and sloped toward both ends, folded tight at the entrance end and folded with a space at the exit end to permit the underfolded edge of the material to pass through said space, a first plate cooperating with the folded portion of said baseplate for forming an upwardly inclined channel from the entrance end to the apex for directing the edge of limp material passing therethrough upward, said first plate having an external lip coupling with said baseplate remote from said inclined channel, a material edge underguide plate forming an overhead channel overlapping a portion of said upwardly inclined channel and extending therebeyond for directing the upwardly directed edge under said inclined ramp for underfolding the edge of said material, said underguide plate including an edge remote from said overhead channel coupling said material edge underguide plate to said baseplate remote from said overhead channel and a fold-tightening plate for forming a fold-tightening channel connecting with said overhead channel, said fold-tightening plate including a lip remote from said fold-tightening channel coupling said fold-tightening plate to said baseplate at a position remote from said fold-tightening channel.
 4. An apparatus for processing a sheet of limp material into flat articles such as bedsheets, towels, drapes, covers, and the like, in which a cut edge of the limp materials is folded over to form a major fold and then the cut edge of the limp material is underfolded beneath said major fold in readiness for stitching to form a finished hem of the flat article, an underfolder device for underfolding the cut edge beneath a major fold thereof comprising: a baseplate having an edge portion thereof folded up and over above the basePlate to form an inclined ramp having an elevated apex intermediate said ramp, said ramp extending upwardly to said apex at the forward end of the baseplate and extending downwardly form said apex to the rear end of the baseplate, said folded portion of said baseplate being spaced above the baseplate at the rear end of the baseplate to provide clearance for the underfolded cut edge to pass beneath the downwardly extending portion of said ramp, a first plate spaced above the upwardly sloping portion of said ramp for defining an upwardly sloping channel, an extending part of said first plate extending away from said ramp and connected to said base at a position remote from said upwardly sloping channel, an inverting plate having a tapered portion adjacent to and aligned with the downwardly sloping portion of the ramp for deflecting the cut edge into the clearance space beneath said downwardly sloping ramp portion, an extending part on said inverting plate extending away from said ramp and connected to said base at a position remote from said ramp, a fold-tightening plate positioned above and spaced from the downwardly sloping portion of the ramp defining a fold-tightening channel, and an extending part on said fold-tightening plate extending away from said ramp and connected to said base at a position removed from said ramp. 